Kai U.s.a., Ltd.

Darrell Lewis

Craig Green

A process for forming knife blades such as for kitchen or sport knife use comprises injecting a compound including a binder and a metallic powder into a mold having a shape of the knife blade, removing a green blank from the mold and sintering the green blank to produce a sintered blank. The sintered blank is then subjected to a hot-isostatic-pressure to produce a finished blank. An insert may be placed in the mold to impose a desired feature, such as a logo or legend, on the green blank during the molding process. The mold is so configured as to changeably receive the insert so that a first series of blanks can be made using the insert, then a new insert may be emplaced to impose a different feature on succeeding blanks formed in the mold. An edge component may be placed in the mold, around which the blank is injected, to form a compound blade.

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Lexington, KY, United States of America

Darrell Lewis